Torch assembly for heating glassy tubes

ABSTRACT

A preform tube (31) is caused to be collapsed into a preform rod by causing a heat zone (54) provided by a torch assembly (50) to traverse the tube longitudinally in a plurality of passes. During this so-called collapse mode, a muffle tube (100) encloses that portion of the tube which extends through the torch assembly. Advantageously, the muffle tube projects a predetermined distance beyond one major face of the torch assembly. The torch assembly comprises annular semi-circular end plates and an annular semi-circular center portion having a plurality of exit ports through which gases are directed into engagement with the tube. The center portion is caused to be recessed between the end plates thereby causing the heat zone generated by the gases to be narrowed. The narrowing of the heat zone and the substantial confinement of the heat energy within the muffle tube cooperate with increased gas flow rates to cause the tube to be collapsed in a time period which is substantially less than that achieved by prior art methods.

This is a division of application Ser. No. 07/537,201 filed Jun. 12,1990 now U.S. Pat. No. 5,090,978 which is a continuation of applicationSer. No. 07/238,373 filed Aug. 30, 1988 now abandoned.

TECHNICAL FIELD

This invention relates to apparatus for heating glassy tubes. Moreparticularly, this invention relates to apparatus to facilitate collapseof an optical preform tube into a preform from which optical fiber isdrawn.

BACKGROUND OF THE INVENTION

There are several different techniques for producing optical fiber foruse in communications. One such technique comprises directing aconstantly moving stream of reactants and oxygen through a glasssubstrate tube having a generally circular cross-section. The oxygenstream carries silicon tetrachloride and dopants to produce the desiredindex of refraction in the finished optical fiber. The substrate glassis heated to a reaction temperature within a moving hot zone thattraverses the length of the tube, and the consequent reaction producesdoped silicon dioxide fused into a continuous layer on the inner wall ofthe tube. The resulting tube is referred to as a preform tube. See forexample, U.S. Pat. No. 4,217,027 which issued on Aug. 12, 1980 in thenames of J. B. MacChesney and P. B. O'Connor.

A torch assembly for heating a glass substrate tube to facilitatedeposition of the reactants in the above-described process is describedin U.S. Pat. No. 4,231,777 which issued on Nov. 4, 1980, in the names ofB. Lynch and F. P. Partus. See also U.S. Pat. No. 4,401,267 which issuedon Aug. 30, 1983 in the name of C. D. Spainhour. Initially, one end ofthe tube is supported in the headstock of a lathe and the other end iswelded to an exhaust tube that is supported in the tailstock.Combustible gases are directed through a housing and gas outlets of thetorch assembly and toward the tube as it is turned rotatably about itslongitudinal axis and as the torch assembly is moved therealong on acarriage to produce a moving hot zone. A temperature profile is producedacross the hot zone which moves along on the surface of the tube toaccomplish the desired reaction and deposition. See F. P. Partus, and M.A. Saifi "Lightguide Preform Manufacture" beginning at page 39 of theWinter 1980 issue of the Western Electric Engineer.

During a deposition mode, the torch carriage moves slowly from theheadstock of the lathe where dopants are moved into the glass tube tothe tailstock where gases are exhausted. At the end of each pass fromheadstock to tailstock, the torch carriage is returned rapidly to theheadstock for the beginning of another cycle. The ends of the gasoutlets adjacent to the tube are cooled to eliminate substantiallydegradation by oxidation or reduction, for example, of the materialforming the housing and gas outlets. In one embodiment of thistechnique, a plasma is established in the tube to enhance certainprocesses in reaction and deposition.

Subsequent to the deposition mode, a collapse mode is used to cause thepreform tube to become a solid rod-like member which is called apreform. It is this preform from which lightguide fiber is drawn. See D.H. Smithgall and D. L. Myers "Drawing Lightguide Fiber" beginning atpage 49 of the hereinbefore identified Winter 1980 issue of the WesternElectric Engineer.

In order to collapse the preform tube, the torch assembly is moved in anumber of passes from the headstock to the tailstock and then in aplurality of passes from the tailstock to headstock. The temperature ofthe moving hot zone which is higher during the collapse mode than duringthe deposition mode softens the tube wall and allows surface tension tocause the tube to collapse into a rod. During the collapse mode,straightening methods disclosed in U.S. Pat. No. 4,477,273 which issuedon Oct. 16, 1984 in the names of B. Lynch and F. P. Partus may be usedto cause the resultant preform to be substantially straight. The processof collapsing a preform tube may consume as much time as four andone-half hours.

There has long been a desire to reduce the time required to collapse apreform tube into a preform. A solution to this problem will yieldsignificant dividends as the costs are directly proportional to the timerequired for this step.

Seemingly, the prior art is devoid of a solution to this problem.Techniques have been proposed but none has met wide acceptance. Anacceptable solution to this problem which should be able to be used withpresent straightening techniques should yield a lower cost preformhaving exceptional straightness.

SUMMARY OF THE INVENTION

The foregoing problem of the prior art has been solved by the apparatusof this invention. A method of heating a tube to induce its collapseincludes the step of supporting the tube at its ends for rotation abouta longitudinal axis thereof. An outer surface of the tube is heated bydirecting a flow of gases through a torch assembly toward a portion ofthe length of the tube. Each successive increment of length of the tubeis exposed to a zone of heat having a temperature profile by causingrelative motion between the zone of heat and the tube while the tube isbeing rotated. As the tube is rotated, it is collapsed into a solid rodas the heat energy is confined and directed in a narrow band intoengagement with the tube. At least a substantial portion of the zone ofheat is confined about substantially the entire circumference of thetube along a portion of the length of the tube. The heat energy isconfined by a muffle tube which overhangs at least one side of the torchassembly and which encloses the circumference of that portion of thetube which extends through the torch assembly and an additional portionof the tube which extends beyond the torch assembly. Gases are caused tobe directed from the torch assembly into engagement with the portion ofthe length of the tube in a manner which results in a relatively narrowmaximum temperature portion of the zone of heat. This is accomplished bycausing the flow paths of the gases as they emerge from passageways ofthe torch assembly to be confined laterally for a predetermineddistance.

In the manufacture of a preform tube from which optical fiber is drawn,a substrate tube, having a generally circular cross-section, issupported rotatably at its ends. The substrate tube is turned rotatablyand heated to an initial temperature while doped reactants are depositedin the tube to form a predetermined profile. During deposition, thetemperature of the tube is increased from the initial temperature as thenumber of passes increase. Then, the outer surface of the tube is heatedto a temperature within a range which is higher than the initialtemperature by the moving zone of heat and the tube is collapsed into arod in accordance with the foregoing method. Afterwards, optical fiberis drawn from the rod.

In an apparatus for collapsing an elongated glass preform tube having acircular cross-section and a deposited core, facilities are provided forholding ends of the tube to allow rotation about its longitudinal axis.The apparatus includes a torch for heating the preform tube. Relativemotion is caused between a zone of heat which is produced by the torchand the preform tube in a plurality of passes to cause successiveincrements of the length of the tube to be heated while it is turnedrotatably.

The heat energy provided by the torch is confined by a muffle tube whichencloses the preform tube from one side of the torch to the other for apredetermined distance on that side of the torch which is the trailingside during an initial portion of the deposition mode.

Further, the torch is modified to optimize the application of themaximum temperature portion of the heat zone. This is done by recessinga center portion of the torch which includes exit ports for thecombustible gases with respect to portions contiguous thereto, therebycausing the heat zone to be narrowed. As a result, the heat energy issomewhat confined and is more concentrated. The use of the muffle tubein cooperation with the partial confinement of the flow paths of thegases causes collapse in a substantially shorter period of time thanwith prior art apparatus.

BRIEF DESCRIPTION OF THE DRAWING

Other features of the present invention will be more readily understoodfrom the following detailed description of specific embodiments thereofwhen read in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective view of an arrangement which is used to depositlayers of glassy materials on an inner wall of a glass substrate tube toprovide a perform tube and for then causing the tube to be collapsedinto a preform from which optical fiber is drawn;

FIG. 2 is a view of a portion of a torch assembly, a portion of astraightening device and a temperature profile across a zone of heatwhich traverses the tube;

FIG. 3 is a perspective view of a torch assembly comprising a muffletube which encloses that portion of the preform tube that extendsthrough the torch assembly and which extends to one side of the torchassembly and also comprising provisions for narrowing the zone of heat;

FIG. 4 is an exploded perspective view of portions of the torchassembly; and

FIGS. 5 and 6 are alternative embodiments of the muffle tube.

DETAILED DESCRIPTION

Referring now to FIG. 1, there is shown an apparatus, designatedgenerally by the numeral 30, for heating and collapsing a glass tube tomanufacture a solid silica glass preform from which a optical fiber isdrawn. During a deposition mode, a substrate tube 31 is heated in orderto cause the reaction products of gases and/or dopants being fed intothe tube to be fused to the inside wall thereof to provide a preformtube having an optically suitable profile for communications use. Inthis description, the numeral 31 is used to designate both the substratetube and the preform tube. The heating of the glass tube 31 is carriedout while gas phase reactants are delivered to the tube. A system forthis delivery is disclosed in U.S. Pat. No. 4,276,243 which issued onJun. 30, 1981, in the name of F. P. Partus.

The apparatus 30 generally comprises a lathe 32 having a headstock 33and a tailstock 34 which are used to support the glass starting tube 31for rotation about its longitudinal axis 36. The lathe 32 also includesa carriage 40 which is mounted for reciprocal movement along the lathe.Mounted on the carriage 40 is a torch assembly which is designatedgenerally by the numeral 50 and a collapsing device which is designatedby the numeral 51.

The torch assembly 50 is adapted to cause a flow of combustible gases toproduce flames which are directed toward the tube 31. By confining theheat from the burning gases to a desired surface area of the tube, thetorch assembly 50 establishes a zone of heat 54 (see FIG. 2) having atemperature profile 55 at the surface of the tube. The mounting of thetorch assembly 50 on the carriage 40 and its movement relative to thetube 31 causes the zone of heat, which may be referred to as a hot zone,to be moved along the length of the tube. The torch assembly 50 issupported by a bracket 53 which is supported from a post 57 that ismounted on the carriage 40. Through adjustment of the bracket 53, thetorch assembly 50 may be moved within any one of a range of distancesfrom the tube 31 or to any one of a plurality of positions about andspaced from the tube.

The torch assembly 50 is described in relation to its use for heatingglass tubes as material is deposited on the inside surface thereof andto provide elevated temperatures to collapse such tubes. However, suchdescription is for purposes of exposition and not for limitation for theinstant torch assembly may be used advantageously to heat other articleshaving various geometries.

The torch assembly 50 in the perspective and exploded views shown inFIGS. 3 and 4 is comprised of first and second identical outerplate-like members 62 and 64, respectively, and a gas outlet plate 66,with the outer members having coextensive arcuate surfaces. The outermembers 62 and 64 each have an arcuately shaped plenum 68 and an inputconduit 72 communicating therewith. Also, the first and second outermembers 62 and 64 each have a channel 74 connected to a connectingconduit 75 and to a cooling tube 76. A plurality of threaded holes78--78 pass through the member 62 and a plurality of holes 79 passthrough the member 64. The gas outlet plate 66 includes an inner arcuatesurface 80.

As can be seen in FIGS. 3 and 4, the gas outlet plate 66 has a firstplurality of radially disposed grooves or slots 82--82 machined in afirst major surface 84 and a second plurality of radially disposedgrooves or slots 86--86 machined in a second major surface 88. Thegrooves 82 and 86 open to the surface 80. The gas outlet plate 66 alsohas a plurality of holes 92--92 therethrough which become aligned withthe holes 78--78 and 79--79 of the outer members 62 and 64 when theouter members are assembled with the gas outlet plate.

FIG. 3 is a perspective view of the torch assembly 50 which is assembledby capturing the planar gas outlet plate 66 between the outer members 62and 64 and securing the component parts together with a plurality ofbolts 94--94 which pass through the holes 78, 79 and 92. It can be seenfrom FIG. 3 that the planar gas outlet plate 66 separates the twoplenums 68--68 and that the radial lengths of the grooves is sufficientto communicate from the vicinity of arcuate outer surfaces 96 and 98 ofthe torch assembly 50 to the plenums 68--68 of members 62 and 64,respectively. Although in an embodiment shown in FIGS. 3 and 4, thegrooves 82 and 86 are interleaved, other arrangements such as alignedgrooves or offset grooves can be used effectively depending on factors,such as, for example, the gases used, the surface mixing required, andthe desired temperature.

In a particular exemplary embodiment depicted in FIG. 3, the outermembers 62 and 64, as well as the plate 66, were made of stainless steeland the tubing 76 was made of stainless steel. Of course, other suitablematerials may be used.

In operation, a substrate tube 31 is supported by the headstock 33 andthe tailstock 34 of the lathe 32 and is caused to be rotated. Thenoxygen is directed into the plenum 68 of the outer member 62 via theconduit 72 while hydrogen is flowed into the plenum 68 of the outermember 64 via the conduit 72. The oxygen and the hydrogen gases arecaused to pass from the plenums 68--68 and exit through the grooves 82and 86, respectively, as alternating jets. The gases will mix at thesurface 80 of the torch assembly 50 and are ignited to form a flamewhich is directed into engagement with the tube 31. The torch assembly50 is moved repeatedly along the length of the substrate tube in aplurality of passes from the headstock 33 to the tailstock 34 to providesufficient heat to fabricate an optical preform as described in detailin U.S. Pat. No. 4,217,027 which is incorporated by reference hereinto.A coolant, such as water, is passed through each tube 76, to maintainthe temperature of the arcuate surface 80 low enough to prevent oxidesfrom forming on the surface thereof to prevent subsequent ejection ofparticulate matter which can contaminate the surface of the preformduring fabrication. Such particulate matter can adversely affect thestrength of a fiber drawn therefrom. Although, the instant embodiment ofeach outer plate is connected to a coolant tube 76, various othertechniques may be used. Also, although the exemplary torch assemblyprovides an oxygen-hydrogen mixture, other suitable gas combinations canbe used.

Typically, the chemical materials for deposition are supplied to thesubstrate tube at its headstock end. Gases are exhausted at thetailstock end. In a deposition mode, the torch is moved in a pluralityof passes from the headstock toward the tailstock.

After the deposition mode, the torch assembly is moved initially in twopasses from the headstock 33 to the tailstock 34 in a collapse mode.During the collapse mode, the flow rates of the gases are increasedsubstantially. Then the exhaust end of the preform tube is pinched offand the torch assembly moved in a pass from the tailstock to theheadstock. Further as can be seen in FIG. 1, the straightening device 51is provided with a roller 90. The roller 90 is moved into engagementwith the preform tube at predetermined times during the collapse modesuch as after the initial two passes of the collapse mode to cause thetube to be straightened. Such a roller and its operation are describedin priorly mentioned U.S. Pat. No. 4,477,273 which is incorporated byreference hereinto. Subsequently, two additional passes are made fromthe tailstock to the headstock to complete the collapse of the preformtube into a preform rod having a diameter in the range of from about16.5 mm to about 18.1 mm. From this rod, optical fiber is drawn. SeeU.S. Pat. No. 4,370,355, which issued on Jan. 25, 1983 in the name of P.J. Niesse and which is incorporated by reference hereinto.

The apparatus 30 of this invention includes additional features whichcooperate with the portion of the apparatus described thus far to reducethe collapse time. The torch assembly includes a muffle tube 100 whichis supported by the outer members 62 and 66 with an inner surface 102 ofa portion 104 thereof being somewhat of a continuation of inner surfaces96 and 98 of the outer plates. The muffle tube 100 includes an opening105 to provide access to the preform tube for a pyrometer 106. An outerperipheral surface 109 of the muffle tube 100 has a radius greater thanthe inner radii of the outer torch members 62 and 64 with radialsurfaces of the one portion 104 of the tube engaging radial portions 111and 113 of the outer members.

Another portion 115 of the muffle tube 100 extends from the one portion104 toward the headstock 33 and overhangs the outer member 64. It issupported by brackets 117--117 which are held in position by straps119--119. The length of the overhang is determined as a function ofcarriage speed and the desired temperature profile of the heat zone 54.

It is preferred that the muffle tube overhang only that side portion ofthe torch assembly 50 which is oriented toward the headstock 33. This isrequired so that during relatively high speed passes when the maximumtemperature portions of the heat zone 54 experience a maximum lag fromthe centerline of the torch, the maximum temperature portion will beenclosed by the muffle tube.

Overhang of the muffle tube also is important with respect to the amountof useable preform tube provided by the process of this invention. Theuseable portion of the preform tube begins several centimeters from theheadstock. As a result, although an overhang of the torch assembly 50 atits headstock side prevents the torch assembly from engaging theheadstock on each pass, this does not decrease the amount of useablepreform. At the other end however, the useable preform begins at thetailstock. Therefore, if anything such as a muffle tube extensionprevents the torch assembly from reaching the tailstock on each pass,there would be a reduction in the amount of useable preform. Themagnitude of the reduction depends of course on the amount of theoverhang, if any, on the tailstock side of the torch assembly.

The torch assembly 50 is configured to optimize the application of thezone of heat to the preform tube to collapse the tube into a preformrod. As can be seen in FIGS. 1 and 3, the arcuate surface 80 of themiddle plate 66, that is the plate which is slotted to provide egressfor the gases, is recessed between the outermost members 62 and 64. Inother words, the radius of the innermost surface 80 of the slotted plate66 is greater than the radii of the innermost surfaces of the outermembers. In a preferred embodiment, the radius of the slotted plate of aconventional torch is increased by about 0.15 cm. In the preferredembodiment, the inner radius of each outer member 62 and 64 is 3.44 cmwhereas the inner radius of the gas outlet plate that is, the radius tothe surface 80 of the gas outlet plate to which the slots open is 3.59cm.

A recessed gas outlet plate 66 in cooperation with the muffle tube 100has been found to be advantageous both during deposition and collapse.As a result of the recessing, the maximum temperature portion of theheat zone is narrowed and hence is more concentrated than that of theprior art. During deposition, the flow rates of the gases aresubstantially less than during the collapse mode. This together with themuffle tube causes the zone of heat to be widened. However, duringcollapse, increased flow rates result in a narrow zone of heat. Also,the narrower the heat zone, the more controlled is the temperatureprofile and the less the time required to collapse the substrate tube.

In the operation of the apparatus 30 in a collapse mode, it is usual touse a first collapse pass in which the torch assembly is moved from theheadstock toward the tailstock at a speed of 7.80 m/min. A second passin the same direction is accomplished at a speed of 6.60 m/min. Third,fourth and fifth passes in an opposite direction, that is from thetailstock toward the headstock, are caused to occur at speeds of 4.8, 3and 3 m/min, respectively.

At the higher speeds of the first two passes, the maximum temperature ofthe heat zone profile (see FIG. 2) lags the portion of the heat zonedisposed between the two outer torch members 62 and 64. However,inasmuch as the muffle tube overhang is disposed on that side of thetorch assembly 50 which is oriented toward the headstock, the maximumportion of the heat zone occurs within the overhanging portion of themuffle tube. As a result, maximum heat energy continues to be confinedwithin the muffle tube circumferentially about the tube 31notwithstanding the speed of the carriage 40. Hence the muffle tube 100is effective to concentrate the heat energy to be applied to thatportion of the tube which is disposed within the muffle tube.

In the last three passes during collapse, the carriage speed is lessthan during the first two. Therefore, even though the overhangingportion of the muffle tube 100 is disposed during those passes on theleading side of the torch assembly, the lag of the temperature profilefrom a symmetrically disposed profile is not that great. As a result,even during these passes, the zone of heat is confined substantiallywithin the muffle tube 100.

The recessed gas outlet plate cooperates with the muffle tube 100 andits overhanging portion 115 to maximize the applied heat energy at thecarriage speeds disclosed. It has been found that the amount by whichthe gas outlet plate is recessed is critical. If too little or if toomuch, the resulting preform may include excess curvature. It has beenfound that a recess on the order of about 0.15 cm is preferred andprovides the best results.

What is important is the cooperation among the carriage speed, theamount of recess of the slotted plate 66 and the length of the muffletube 100. One or all of these variables may be changed in order tocontrol the temperature profile of the zone of heat and the timerequired in order to cause the perform tube to become collapsed into apreform rod. It has been found that the use of the methods and apparatusof this invention reduces the time required to collapse the preform tubeinto a rod by about twenty-five percent.

For the deposition mode, the heat zone is about the same as that foundduring deposition with a torch not having a muffle tube nor a recessedgas outlet plate. On the other hand, the use of a torch assembly havinga muffle plate and recessed gas outlet plate allows the use of lowerflow rates for the gases during deposition, thereby resulting insignificantly lower gas consumption. Nevertheless, even though the flowrates are lower, the muffle tube reradiates heat energy and causes theheat zone to be about as broad as without the muffle tube and recess.

As mentioned earlier, the recessed gas outlet plate results in anarrowed heat zone. The relatively narrow heat zone cooperates with themuffle tube to provide higher temperatures. Further, during collapse,the gas flow rates are substantially greater than those used duringdeposition, but approximate those used for a torch not having a recessedgas outlet plate and muffle tube. Because of the cooperation among thenarrower heat zone, the muffle tube and the higher flow rates, theforces of the gases on the preform tube are greater. This reduces thecollapse time by about twenty-five percent.

The torch assembly 50 may be repaired simply by replacing any of thethree basic components, i.e., the outer members 62 and 64 and the gasoutlet plate 66. Furthermore, the heat zone and the flame pressure areasprovided by the torch assembly 50 may be modified by simply changing thesize of the grooves 82 and 86 and/or the thickness of the gas outletplate 66 and or by the amount by which the gas outlet plate is recessed.

Although the muffle tube 100 in the preferred embodiment is caused tooverhang one of the outer members 62 or 64, other embodiments may beused. In FIG. 5 is shown a muffle tube 120 which overhangs both sidemembers 62 and 64. Remembering that the side member 64 is orientedtoward the headstock, the overhang of the muffle tube 120 from the sidemember 64 may be greater than that past the side member 62.

In FIG. 6, there is shown another embodiment of a muffle tube. Therein amuffle tube 130 is caused to extend only from an outer surface of oneside member 62 to an outer surface of the other side member 64. Themuffle tube 130 is held in position by clamps 132--132.

It is understood that the above-described arrangements are simplyillustrative of the invention. Other arrangements may be devised bythose skilled in the art which will embody the principles of theinvention and fall within the spirit and scope thereof.

I claim:
 1. A torch assembly comprising:a gas outlet plate; first andsecond outer members arranged such that said gas outlet plate iscaptured therebetween; each outer member having a cavity therein whichopens toward said gas outlet plate which isolates said cavities; inletmeans for directing gas into each cavity; said gas outlet plate having aplurality of slots on each major surface thereof, arranged in aninterleaved relationship, the slots extending from the respectivecavities in the outer members to an inner arcuately shaped surface ofsaid gas outlet plate to form a plurality of gas outlets; and the innerarcuately shaped portion of said gas outlet plate having a radius whichis greater than that of adjacent inner arcuately shaped surfaces of saidouter members thereby controllably narrowing the width of a gas pathcreated by gas being directed out of the torch assembly.
 2. The torchassembly of claim 1, which also includes a tubular member for enclosingthe arcuate surface of said gas outlet plate and the outer members andextending for a predetermined distance beyond one side of one of saidouter members.